Modular building construction

ABSTRACT

A modular building construction formed from a plurality of shell modules coupled together and reinforced by poured-in-place reinforced concrete vertical pillars interlinked with poured-inplace horizontally extending concrete slabs. Said shell modules serve as both an integral part of the building construction and as a form for said poured-in-place concrete.

United States Patent [111 3,861,093 Robinson Jan. 21, 1975 [54] MODULAR BUILDING CONSTRUCTION 960,205 4/1950 France 52/236 1,269,321 7/1961 France 52/79 [76] Invent Steve 1 67th 2,076,803 6/1971 France 52/79 New o k, NY. 1 23 802,658 711951 Germany 52/236 p 649,376 9/1937 Germany 7. 52/236 [21] Appl. No.: 354,021

Primary Examiner-Ernest R. Purser Assistant Examiner-Henry Raduazo [52] US. Cl 52/79, 52/236, 52/237 Attorney, Agent, or Firm B]um, Moscovitz, Friedman [51] Int. Cl E04b 1/348 & Ka Ian [58] Field of Search 52/79, 236, 237, 234, 220, p

[56] References Cited [57] ABSTRACT UNITED STATES PATENTS 2,000,243 5/1935 Manske 52/220 A modular building construction formed from a P!- 2,065,433 12/1936 Percum 52/220 ty f hell modules coupled together and rem- 3,289,370 12/1966 Van Etten 52/220 forced by poured-in-place reinforced concrete vertical 3,331,170 7/1967 Lowe 52/79 pillars interlinked with poured-in-place horizontally 3,703,058 11/1972 Klett 52/236 t ding on rete slabs, Said shell modules serve as 3,723,022 3/1973 Daltner 1 52/79 both an integra] part f h building construction and 3,77 ,528 12/1973 Heifetz 52/220 as a form for Said poured in place Concrete FOREIGN PATENTS OR APPLICATIONS 1,269,080 7/1961 France 52/236 21 Claims, 7 Drawing Figures my .1- .mmaur gm. ;.1 a:

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SHEET 3 BF 3 MODULAR BUILDING CONSTRUCTION BACKGROUND OF THE INVENTION This invention relates to modular building constructions. It has long been recognized that conventional construction techniques requiring on site construction of an entire building are uneconomical and that alternate approaches are required. Within the last decade, many modular housing approaches have been introduced, principally relying on conventional construction materials such as wood, steel and concrete. By moving the work into the factory, some cost savings have been achieved by reducing the high cost of on-site labor and delays due to weather. However, these savings are often offset by the high cost of transporting the modules from the factory to the site, thereby minimizing the impact on the final cost of the developer and occupant. In addition, such prior art modular dwelling units have rarely proved to be superior to that of the traditional on-site dwelling constructions.

The modular building construction in accordance with the invention avoids the foregoing deficiencies by providing a light weight module readily assembled at the site, yet through the use of poured-in-place concrete, provides the structural integrity required.

SUMMARY OF THE INVENTION Generally speaking, in accordance with the invention, a modular building construction is provided having a plurality of shell modules, each of said shell modules having a roof and side walls, the bottom of said module being essentially open. Said side walls are formed to define at least two corners positioned for registration with corresponding corners of other of said modules, said corners being shaped to define a space between the outer periphery thereof and the projection of the adjacent side wall portions. The combined spaces defined by the aligned corners of adjacent modules defines a vertical column for receipt of reinforced concrete. The top portion of each module is formed with a circumferential projection except in the region of said corners, said projection being spaced from the periphery of the sides of said module. Said projection defines a well for receipt of concrete communicating with the concrete of said vertical pillars.

Said projection also serves to receive the bottom periphery of the side walls of a further module position in overlapping relation above the top of one of said modules. Said modules may be secured together by bolts.

Said projection may be defined by a corresponding channel on the inner surface of said module adapted to receive utilities, a cover plate being provided for said channel. The modules may be formed of a core of rigid urethane having glass fiber reinforced facings bonded thereto.

Accordingly, it is an object of the invention to provide a modular building construction which permits formed from lightweight modules capable of construction off-sites.

A further object of the invention is to provide a modular building construction which is readily assembled on-sites, and which uses poured-in-place concrete as the principal structural support.

BRIEF DESCRIPTION OF THE DRAWINGS For a fuller understanding of the invention, reference is had to the following description, taken in connection with the accompanying drawings, in which:

FIG. 1 is a cross-sectional side elevational view of a structure incorporating the modular housing construction in accordance with the invention;

FIG. 2 is a sectional perspective view of a building incorporating the modular building construction in accordance with the invention;

FIGS. 3, 4 and are sectional views taken along lines 3-3, 44 and 5-5 perspectively of FIG. 2;

FIG. 6 is a top sectional view of a housing construction in accordance with the invention; and

FIG. 7 is a sectional view taken along lines 7-7 of FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The modular housing construction in accordance with the invention is formed from a plurality of modular units, each of said modular units being defined by a shell module. The basic shell module is an essentially rectangular unit 10 depicted in FIGS. 2 and 6. This basic shell module, which is formed of a multi-layered plastic material as more particularly described below, has four side walls 12 and a top wall 14. The bottom of the shell module 10 is open for interlocking relations with other modules as more particularly described below. Side walls 12 intercept at an inclined corner wall 16, the outer periphery 18 (FIG. 3) of which defines a space with the projection of side walls 12. When four of such modules are positioned in abutting relation, as shown in FIGS. 3 and 6, corner walls 16 define a vertical column 20 of essentially square cross section. As best shown in FIGS. 2 and 4, the upper periphery of side walls 12 is formed with an inward stepped region 22 defining an essentially horizontal seat 24. Top wall 14 is formed with four channels 26 on the inner surface thereof projecting upwardly and extending parallel to side walls 12. The outer peripheral side wall of each channel 26 is a vertical extension of stepped region 22 of the corresponding side wall. Channels 26 terminate at ends 28 (FIG. 2) in the region of corner walls 16.

As best shown in FIGS. 1, 2 and 4, stepped regions 22 of side walls 12 are dimensioned to receive the lower peripheral portion of the side walls 12 of another of modules 10. Thus, if two modules 10 are disposed in side-by-side relation with corresponding side walls 12 in engagement, the stepped region 22 of the two side walls defines a channel for receiving the lower peripheral ends 30 of the corresponding side walls of two further shell modules. The lower edges 32 of peripheral portions 30 of said side walls rest on the corresponding seats 24 of the lower shell module. Lower peripheral regions 30 of the upper shell modules and the stepped regions 22 of the lower modules are secured together by means of a plurality of horizontally aligned spaced bolts 34 and nuts 36 (FIG. 4). The heads and ends of said bolts and the nuts project into channels 26. Further, as shown in FIG. 3, each adjacent pair of side walls are secured by a vertical line of spaced bolts 38 and nuts 40 positioned adjacent the intersection of side walls 12 and comer walls 16 (FIG. 3).

The vertical column defined by the four angled corner walls 16 of four adjacent shell modules 10 is filled with concrete 42 (FIG. 3). Said column of concrete is reinforced by a vertically extending reinforcing cage 44 consisting of four vertically extending steel rods 46 LII maintained in position by a plurality of vertically spaced substantially rectangular supports 48.

The projection of channels 26 defines a well in the upper surface of top wall 14 which receives and retains a slab 50 of concrete. Said slab is reinforced by a grid of steel rods 52 (FIGS. 2 and maintained in spaced relation to the upper surface of top wall 14 by a series of spaced feet 54. As shown in FIGS. 2 and 7, concrete slab 50 is coupled to concrete pillar 42 by a connecting concrete portion 56 extending between ends 28 of channels 26 and between slab 50 and column 42. For this purpose, corner walls 16 are provided with a cut out region 58 (FIG. 7) at the bottom thereof. Said cutout region preferably starts at a point at the surface 60 of concrete slab 56. Further reinforcing rods 62 extend through connection portion 56 and are preferably coupled to rods 52 and cage 44. While grids of steel reinforcing rods are depicted in the drawing, other suitable reinforcement means may be used. Where bolts are depicted to connect modules, suitable glues may be used.

Referring now to FIGS. 1, 2 and 6, the assembly of the building construction in accordance with the invention will be described. A suitable concrete slab foundation 64 would be poured at the site. Other forms of foundations such as are required for specific ground conditions may be used. The shell module defining the first floor of the building would then be secured, as by bolting, to that foundation. Thus, as shown in FIG. 1, a special stair well module 66 would be bolted to other modules, such as the module 10, by measn of bolt 38. Outer corners where the columns are not completed by other modules would be provided with special exterior column members 68, 70 and 72 (FIGS. 2 and 6). Exterior column members 68 are essentially V-shaped and are provided with laterally extending flanges for bolting to two adjacent modules. Column members 68 are for use where the outer side walls of the two adjacent modules defining the column to be completed lie in the same plane. Column member 70 consists of a fiat plate and a pair of angled flanges for bolting to the adjacent side walls of two outer modules wherein the modules defining the column to be closed extend at right angles to each other. Finally, column member 72 is channelshaped, defining three walls of the column and having angled flanges for cooperation with two adjacent walls 12 of a single corner module.

A grid of steel rods 74 supported by feet (not shown) would be laid on the concrete foundation slab 64 within each module and concrete would be poured to define the floor 76 of each module. Forms would be placed along the periphery of floor 76 before pouring to define channels 78 for receiving utilities as described below. Channel cover plates 80 would be provided, secured by brackets (not shown) to enclose the floor channel 78. Reenforcing grids 52 would then be positioned on feet 54 in the wall defined by the top wall channels 26 of each module. Reenforcing cages 42 would be positioned in the columns defined by adjacent modules and column members. The connecting reenforcing rods 62 are also positioned between ends 28 of channels 26. Concrete is then poured in the columns and on the top surface of top wall 14 to define the column of concrete 44, slab of concrete 50 and connecting concrete portion 60. The surface of slab 50 and connection portion 56 is slightly below the upper surface 82 of channels 26.

After the concrete has dried, the next level of shell modules is positioned and bolted together and to the first level by means of bolts 34 and 38. The lower peripheral portions 30 of the modules of the second floor would be received within the stepped regon 22 of the modules of the lower floors. The process is repeated, depending on the number of floors with the concrete providing the principle structural integrity of the structure and with the plastic shell members defining forms for the concrete and defining the walls of the rooms of the building. The roof of the top floor may be provided with a concrete slab 84 reenforced by a steel grid 86 but of a thickness equal to the height of the channel 26 of the upper module. The columns can be capped by cap members 88 if desired.

While the basic shell module 10 has a rectangular configuration, with four side walls, other configurations are possible as illustrated in FIG. 6. Thus, module 90 has a rectangular configuration but one of the side walls 92 is opened to provide a room of larger dimensions. Module 94 has a semi-circular cross section. but is provided with at least two corner walls 16 for meshing with the other modules. The combination of modules 90 and 94 produces a pleasing architectural effect, but is illustrated by way of example, and not by way of limitation as to the effects capable of creation.

- Module 66 is a stair-well module of reduced dimensions and preferably pre-fitted at the factory with the stairs 96 illustrated in FIG. 1. As shwon in FIG. 1, the top wall 14' of the lowest stair-well module 66 would be formed with an opening through which the stairs 96 extend into the upper stair-well module 66. Also by way of example, it is seen that said stair-well modules are provided with internal walls 98 and 100, as desired, to define closets and other internal structural areas. At the factory, either during molding or as a cut out after molding, any of the shell modules can be provided with windows 102 or door openings 104 (FIG. 1) to produce a building functionally similar to conventional buildings.

Selected modules can be outfitted at the factory as kitchens, bathrooms, or other rooms through the factory mounting of suitable fixtures. Channels 26 provide chases for the passage of utilities such as electrical wiring, heating ducts and water pipes, all of which can be premounted therein at the factory. Further, the upper surface 82 provides a convenient location for the mounting of heating ducts and electrical outlets. Channel 78 in the concrete slab 76 defining the first floor can serve a similar function with the utilities mounted at the site.

After construction, the interior of the shell modules may be completed by the mounting of corner cover plates 106 which are secured to adjacent side walls 12 by brackets (not shown) so as to conceal the heads of bolts 38, and nuts 40. The passage 107 thus defined can be used for concealing utilities extending between floors or conduits within the columns can be used for this purpose. Further, channel cover plates 108 would be mounted to cover the openings of channels 26 to conceal the utilities therein. Said channel cover plates may also be provided with openings through which heating ducts or light fixtures extend, if desired. The space between the surface 60 of concrete slab 50 and the upper surface 82 of channels 26 permits the laying of a suitable flooring without covering outlets or ducts formed in the surface of channels 82.

The individual shell modules are molded at the factory from a plastic material. In the preferred embodiment, the material of said shell modules consists of an outlet layer 110 of fiber glass, a middle layer 112 of foam urethane and an inner layer of fiber glass. The strength and surface smoothness of the fiber glass layers permit them to be used as the actual inner walls of the building, the floor of each room being defined by the respective concrete slabs.

A mold would be provided for each shell module shape. To form the shell module, a resin suitable for forming fiber glass would be sprayed on the surface of the mold to form a gel coat. Resin and chopped glass fibers would be sprayed together onto said gel coat to a thickness of approximately 1/16 inch. Premolded polyurethane foam would be pressed onto the resinglass fibers mixture while said mix is still wet to insure bonding. Said pre-molded polyurethane foam is preferably of a thickness of about 2 inches. The combination of resin and chopped glass fibers is then sprayed onto the outer surface of said polyurethane foam to a thickness of approximately l/16 inch. Finally, a final resinonly gel coat is sprayed on the outer surface to define the shell module. Preferably, the resin and chopped glass fibers are sprayed from separate nozzles. The resulting shell module is light in weight, yet has the structural strength to function as described above in the modular building construction in accordance with the invention Further, the walls of the shell modules provide good insulation.

It will thus be seen that the objects set forth above, and those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

What is claimed is:

l. A modular building construction comprising a plurality of shell modules in contiguous side-by-side and overlapping relation, each of said shell modules having a top wall and side wall portions, the bottom of said modules being essentially open, said side wall portions being formed to define at least two corner wall portions positioned for registration with corresponding corner wall portions of other contiguous shell modules and each having an outer surface, said corner wall portions being shaped to define a space between the outer surface thereof and a projection of the adjacent side wall portions so that the combined spaces defined by the aligned corner wall portions and contiguous modules defines a vertical column, said top wall being formed with upwardly extending circumferential projections except in the region of said corner wall portions, each of said circumferential projections having an outer side wall spaced inwardly from the outer surface of said side wall portions to define a seat for the receipt of the lower peripheral edges of side wall portions of shell modules positioned above said top wall portion; and poured-in-place concrete in said vertical columns, and in the region on the upper surface of said top wall between said projections including the region of said corner wall portions.

2. A modular building construction as recited in claim 1, including vertically extending reinforcing means within the concrete of said vertical columns.

3. A modular building construction as recited in claim 2, including reinforcing grid means within the concrete received in the region between said projections.

4. A modular building construction as recited in claim 3, including connecting reinforcing means in the region of said concrete intermediate the region between said projections and said column.

5. A modular building construction as recited in claim 1, wherein said side wall portions of said shell modules are formed with an inwardly stepped portion at the upper periphery thereof in registration with the outer side of said projections for defining said seat for receipt of the lower peripheral edges of the side wall portions of the upper overlapping modules.

6. A modular building construction as recited in claim 5, including a plurality of horizontally spaced bolts extending through the adjacent stepped side wall region of two contiguous shell modules and the lower peripheral portion of the side wall portions of two further shell modules overlapping said first-mentioned shell modules, which lower peripheral portions are received in the seats defined by said adjacent stepped regions.

7. A modular building construction as recited in claim 6, wherein the inner surface of said projections in said top walls define channels, said bolts being positioned in registration with said channels.

8. A modular building construction as recited in claim 1, including a plurality of vertically spaced bolts extending through the contiguous side wall portions of two adjacent shell modules in a region adjacent said corner wall portions.

9. A modular building construction as recited in claim 8, including a vertically extending, removably mounted comer plate extending between adjacent side wall portions within said shell modules to overlap the adjacent corner wall portions and the projecting ends of said bolts.

10. A modular building construction as recited in claim 1, wherein the inner surface of said projections in said top wall portions define channels, said channels defining utility chases.

11. A modular building construction as recited in claim 10, including channel cover plates removably mounted to close said channels.

12. A modular building construction as recited in claim 1, wherein said corner wall portions are essentially flat and angled relative to the adjacent side wall portions to define an essentially square column.

13. A modular building construction as recited in claim 1, including column forming members dimensioned for engagement against side wall portions of shell modules defining the outer periphery of said building construction in registration with the outer corner wall portions thereof to define vertical columns with said outer corner wall portions.

14. A modular building construction as recited in claim 1, wherein said modular shell is formed of a plastic material.

15. A modular housing construction as recited in claim 2, wherein said shell modules are fonned of a central urethane core having surface layers of fiber glass.

16. A shell module for use in modular building construction having a top wall portion, and side wall portions each having an outer surface and the module having an essentially open bottom, said side wall portions being formed to define at least two corner wall portions each having an outer surface, each said corner wall portion being shaped to define a space between the outer surface thereof and a projection of the outer surface of the side wall portions adjacent to said corner wall portion, said top wall portion being formed with upwardly extending circumferential projections except in the region of said corners, said projections being spaced inwardly from the outer surface of the side wall portions of said module a distance substantially equal to the thickness of said side wall portions of said module.

17. A shell module as recited in claim 16, wherein the side wall portions are formed with an upper peripheral stepped region aligned with the outer side of said projection.

18. A shell module as recited in claim 16, wherein the inner surface of said projections define a channel so as to form a utility chase.

19. A shell module as recited in claim 16, including a cut-out region in the lower periphery of said corner wall portions.

20. A shell module as recited in claim 16, formed of a plastic material.

21. A shell module as recited in claim 20, wherein said shell module is formed with a urethane foam core having fiber glass layers on the surface thereof. 

1. A modular building construction comprising a plurality of shell modules in contiguous side-by-side and overlapping relation, each of said shell modules having a top wall and side wall portions, the bottom of said modules being essentially open, said side wall portions being formed to define at least two corner wall portions positioned for registration with corresponding corner wall portions of other contiguous shell modules and each having an outer surface, said corner wall portions being shaped to define a space between the outer surface thereof and a projection of the adjacent side wall portions so that the combined spaces defined by the aligned corner wall portions and contiguous modules defines a vertical column, said top wall being formed with upwardly extending circumferential projections except in the region of said corner wall portions, each of said circumferential projections having an outer side wall spaced inwardly from the outer surface of said side wall portions to define a seat for the receipt of the lower peripheral edges of side wall portions of shell modules positioned above said top wall portion; and poured-in-place concrete in said vertical columns, and in the region on the upper surface of said top wall between said projections including the region of said corner wall portions.
 2. A modular building construction as recited in claim 1, including vertically extending reinforcing means within the concrete of said vertical columns.
 3. A modular building construction as recited in claim 2, including reinforcing grid means within the concrete received in the region between said projections.
 4. A modular building construction as recited in claim 3, including connecting reinforcing means in the region of said concrete intermediate the region between said projections and said column.
 5. A modular building construction as recited in claim 1, wherein said side wall portions of said shell modules are formed with an inwardly stepped portion at the upper periphery thereof in registration with the outer side of said projections for defining said seat for receipt of the lower peripheral edges of the side wall portions of the upper overlapping modules.
 6. A modular building construction as recited in claim 5, including a plurality of horizontally spaced bolts extending through the adjacent stepped side wall region of two contiguous shell modules and the lower peripheral portion of the side wall portions of two further shell modules overlapping said first-mentioned shell modules, which lower peripheral portions are received in the seats defined by said adjacent stepped regions.
 7. A modular building construction as recited in claim 6, wherein the inner surface of said projections in said top walls define channels, said bolts being positioned in registration with said channels.
 8. A modular building construction as recited in claim 1, including a plurality of vertically spaced bolts extending through the contiguous side wall portions of two adjacent shell modules in a region adjacent said corner wall portions.
 9. A modular building construction as recited in claim 8, including a vertically extending, removably mounted corner plate extending between adjacent side wall portions within said shell modules to overlap the adjacent corner wall portions and the projecting ends of said bolts.
 10. A modular building construction as recited in claim 1, wherein the inner surface of said projections in said top wall portions define channels, said channels defining utility chases.
 11. A modular building construction as recited in claim 10, including channel cover plates removably mounted to close said channels.
 12. A modular building construction as recited in claim 1, wherein said corner wall portions are essentially flat and angled relative to the adjacent side wall portions to define an essentially square column.
 13. A modular building construction as recited in claim 1, including column forming members dimensioned for engagement against side wall portions of shell modules defining the outer periphery of said building construction in registration with the outer corner wall portions thereof to define vertical columns with said outer corner wall portions.
 14. A modular building construction as recited in claim 1, wherein said modular shell is formed of a plastic material.
 15. A modular housing construction as recited in claim 2, wherein said shell modules are formed of a central urethane core having surface layers of fiber glass.
 16. A shell module for use in modular building construction having a top wall portion, and side wall portions each having an outer surface and the module having an essentially open bottom, said side wall portions being formed to define at least two corner wall portions each having an outer surface, each said corner wall portion being shaped to define a space between the outer surface thereof and a projection of the outer surface of the side wall portions adjacent to said corner wall portion, said top wall portion being formed with upwardly extending circumferential projections except in the region of said corners, said projections being spaced inwardly from the outer surface of the side wall portions of said module a distance substantially equal to the thickness of said side wall portions of said module.
 17. A shell module as recited in claim 16, wherein the side wall portions are formed with an upper peripheral stepped region aligned with the outer side of said projection.
 18. A shell module as recited in claim 16, wherein the inner surface of said projections define a channel so as to form a utility chase.
 19. A shell module as recited in claim 16, including a cut-out region in the lower periphery of said corner wall portions.
 20. A shell module as recited in claim 16, formed of a plastic material.
 21. A shell module as recited in claim 20, wherein said shell module is formed with a urethane foam core having fiber glass layers on the surface thereof. 